Asymmetrical electrical connector with aligning means

ABSTRACT

In an electrical connector the plug shell and the receptacle shell contain inserts having both pin type contact members and socket type contact members, the inserts having correspondingly stepped facing surfaces, each of the pin contact members being recessed within an extended portion of such stepped surface.

United States Patent [1 1 11 3,840,839

Smaczny et al. 1 Oct. 8, 1974 1 ASYMMETRICAL ELECTRICAL 2.386.17710/1945 Andersen 339 49 R f 2,521,822 9/1950 Boswell r r 339/49 RCONNECTOR WITH ALIGAII G MEANS 2,824,290 2/1958 Archer et a1 339/49 R[75] Inventors: Charles W. Smaczny, Chicago; 3 129 993 4/1964 R0 4 H339/49 R Roger Floyd Powell. Arlington 3.271.726 9/1966 Pfendler 339/49R Heights; Walter Takiguchi; George 3 berstem both of Chlcago an ofPrimary ExaminerPaul R. Gilliam Assistant ExaminerTerrell P. Lewis [73]Assignee: Akzona Incorporated, Asheville, Attorney, Agent. or Firm-Hill,Gross, Simpson, Van

N.C. Santen, Steadman, Chiara & Simpson [22] Filed: Feb. 1, 1973 [21]Appl. No.: 328,765 [57] ABSTRACT In an electrical connector the plugshell and the recep- [52] 1 339/49 339/90 339/186 M tacle shell containinserts having both pin type contact g 1 members and socket type contactmembers, the inserts having correspondingly stepped facing surfaces,each of the pin contact members being recessed within an extendedportion of such stepped surface.

[56] References Cited UNITED STATES PATENTS 7 Claims, 3 Drawing Figures2,014,853 9/1935 Ley et a1. 339/49 R v C 5/ Z5 r 1 a4 52 r 5g 52 J 62 5e45 PAIENTEDUBT 8% 3,840,839

WEE 2 w E ASYMMETRICAL ELECTRICAL CONNECTOR WITH ALIGNING MEANSBACKGROUND OF THE INVENTION 1. Field of the Invention The presentinvention relates generally to electrical connectors and moreparticularly to connectors having means for preventing the accidentalcoupling of unpaired connector shells having the same size and the samecontact arrangement.

2. The Prior Art In the prior art many connector assembly structureshave been devised, with a variety of schemes for preventing engagementof the two shells of the connector unless they are properly aligned. Insome cases, an asymmetrical contact arrangement is provided, to preventelectrical mating when the shells are not aligned. In other cases, oneor more keys are provided on one shell, and keyways are provided atcorresponding positions on the other shell. While these techniques areeffective, there are occasions when multiple connectors with the samecontact arrangement and with the same arrangement of keys and keywaysare used, and in these circumstances, it is desirable to provide furthermeans for preventing electrical mating of unpaired connector shells.Moreover, even when cooperating keys and keyways are provided, the keysand keyways suffer wear during use, and may, after a time, fail tofunction in a manner which insures proper alignment of the connectors.It is therefore desirable to provide another means for insuring properalignment of the shells of a connector prior to coupling.

SUMMARY OF THE INVENTION In accordance with one embodiment of thepresent invention there is provided an electrical connector having apair of shells containing inserts bearing contact members and means forholding the shells together in coupled relation, the inserts of bothshells having correspondingly stepped facing surfaces, each of saidinserts bearing both pin contact members and socket contact members,such pin contact members being recessed within the extended portion ofthe stepped surface, and the socket contact members extending beyond therecessed portion of the stepped surface.

BRIEF DESCRIPTION OF THE DRAWINGS Reference will now be made to theaccompanying drawings in which:

FIG. 1 is a cross-sectional view of a connector incor porating anillustrative embodiment of the present invention, with the two shellsseparated, the plane of the cross-section passing through the axis ofboth shells;

FIG. 2 is a plan-view of the contact face of one shell of the connector;and

FIG. 3 is a plan-view of the contact face of the other shell of theconnector.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIG. 1 the twoshells 10 and 12 of the connector are shown in separated relationship.The plug shell 10 is adapted to be received within the receptacle shell12. Both the shells 10 and 12 are tubular bodies of generally circularcross-section, and are generally axially symmetric. The shell 10 isprovided with an annular groove 18 which receives a lock ring 20.

into assembled relationship, tightens the coupling and locks the twoshells 10 and 12 together. The shell 12 has a plurality of pins 24equally spaced around the periphery thereof and protruding outwardlytherefrom. The pins 24 are received in notches 26, provided on theinterior of the coupling nut 22. Spiral grooves 28 lead from the notches26 to an annular chamber 30. When the shells 10 and 12 are properlyengaged, the pins 24 are received within the recesses 26 and rotation ofthe coupling nut causes the pins to pass along the grooves 28 until thecoupling nut has been rotated sufficiently as to cause the pins 24 toenter the chamber 30. A plurality of spring members 31, one for each pin24, en-

gage the pins when they enter the chamber 30 andtoward each other untiltheir various cooperating contact members are mated, and in goodelectrical contact with each other.

Each of the shells 10 and 12 contain within the interior thereof aninsert 32 made up of a plurality of platelike layers 34-36 whichcooperate with each other to support a plurality of contact members infixed position. The insert 32 is formed of three layers of relativelyrigid plastic material, all of them generally in the form of rightcircular cylinders. The outermost plate 34, meaning the furthest removedfrom the area between the two unconnected shells 10 and 12, has anoutwardly extending flange 37 which cooperates with an inwardlyextending flange 38 provided on the interior of the shell 10. The flange38 prevents the plate 34 from moving inwardly (i.e., toward the otherconnector shell) in the shell 10. A retaining ring 40 prevents the plate34 from moving outwardly relative to the shell 10. The retaining ring 40has a groove 42 which cooperates with an annular, inwardly extendingprotuberance 41 provided on the inner surface of the shell 10,maintaining the retaining ring 40 in positionrelative to the shell 10therefore also maintaining the plate 34 in the position illustrated. Theinterior of the retaining ring 40 is filled with a circular cylindricalbody 43 formed of elastomeric material and having a plurality ofapertures 44 through which conductors (not shown) may pass to reach thecontact members of the connector. The aper tures 44 are preferablyequally spaced apart, and are aligned with corresponding aperturesprovided in the plates 34-36, in which the contact members 45 and 46 aresupported.

The contact members 45 and 46 are each formed as a body of revolution,having a tubular end portion 47 for facilitating electrical connectionwith conductors passing through the apertures 44, and a spool-like midportion 48. The mid portion of the contact members are surrounded byretainer members 52 having an outer end rim for engaging the innersurface of the plate 34, and an inner end rim for engaging a shoulderformed within the interior of each aperture within the plate 36. Eachretainer member 52 also has a shoulder 53 formed at the inner end of anannular flange located adjacent the outer endrim, which shoulderengagesa shoulder provided within each aperture extending through theplate 35.

The assembly of the insert 32 from three plates 34-36 allows the plates34-36 to be molded, and the required shoulders and flanges are formedwhere they are required, without the need for any unusual moldingtechniques.

The contact members 45 and 46 supported in the inserts 32 each includepin contact members 45 and socket contact members 46. The connector ofthe present invention is an asymmetrical connector because both pincontact members and socket contact members are supported within eachshell. The pin contact members 45 of the shell 10 are aligned in coaxialalignment with the socket members 46 of the shell 12, and viceversa. Thecontact members 45 and 46 are brought into engagement with each other bymoving the two shells together along their common axis, whereby each ofthe socket members receives a corresponding pin member, and establishesfirm electrical contact therewith.

The innermost plate 36 has a stepped inner surface facing the oppositeconnector shell, having an extended portion 54 and a recessed portion56, separated by a step surface 58 which is generally parallel with theaxis of the connector. The extended surface portion 54 ex tends inwardlybeyond the inner ends of the pin contact members 45, while the socketcontact members protrude beyond the plate 36 toward the oppositeconnector shell. An elastomeric body 60 overlies the recessed surfaceportion 56, and the socket members 46 extend through the body 60 andbeyond the extended surface portion 54.

The two inserts 32 for the shells l and 12 are identical, and so theabove description applies equally to both inserts.

When the two connector shells and 12 illustrated in FIG. 1 are to becoupled together, they are aligned coaxially as shown in FIG. 1, andbrought together along their common axis. If they are not angularlyaligned in such a way as to permit engagement of the contacts with eachother, the ends of the socket member 46 bear against the extendedsurface portion 51 of the insert 32, and cannot make contact with any ofthe pin members 45. Contact between mismatched pin contact members andsocket contact members is thereby prevented. Electrical contact is madeonly when the socket contact members 46 can enter the apertures of theplate 36 far enough to engage the pin contact members 45, which occursonly when the alignment is proper.

FIGS. 2 and 3 illustrate the cooperative arrangement of the varioussocket contact members 46 and pin contact members 45 provided for eachof the two connector shells shown in FIG. 1.

The three plates 34-36 which make up the insert 32 are maintained inassembled relationship by virtue of the elastomeric body 60 which bearsagainst the recessed surface 56 of the plate 36. The friction betweenthe elastomeric body 60 and the socket contact members 46 prevents thebody 60 from moving away from the insert 32, and therefore holds thevarious portions of the insert 32 in place. Compression of the body 60during coupling provides a force which maintains the coupling nut 22 inproper position.

The shells 10 and 12 may be provided with cooperating keys and keywaysif desired, and as shown in FIGS. 2 and 3, keys 62-66 are provided onthe shell 10, for

cooperation, respectively, with keyways 72-76 provided on the shell 12.

The shell 12 may be provided, if desired, with a flange having boltholes 82 facilitating mounting the shell in a fixed location. The shell12 also preferably has a resilient sealing ring 84 (FIG. 1) disposedwhere it can be engaged by the inner rim of the shell 10, to establish amoistureproof seal between the shells.

From the foregoing description, it is seen that a connector constructedin accordance with the present invention achieves the function ofpreventing mating of the contact members of the connector when they arenot in properly aligned relationship, irrespective of any key-keywayarrangement. The stepped facing surfaces of the inserts 32, and theextended portions thereof, maintain separation of the various contactmembers until the proper angular alignment is obtained, and positivelyprevent mating with a conventional connector of the same shell size,whether socket type or pin type.

Although the step surface 58 is centrally disposed in the embodimentdescribed above, it will be appreciated that the location and shape ofthe step surface may be modified to prevent mating of unpaired connectorshells of the asymmetrical type. For example, the connector may havemore than half of the contact members on one shell of the pin type, withthe paired shell having more socket type contact members, so that thestep surface 58, as viewed in FIGS. 2 and 3, is not positioned along adiameter of the insert 32. The step 58 may form a plane parallel to theaxis of the connector but spaced from the axis thereof, or mayalternatively form a cylindrical curved surface enclosing a group ofcontact members. In either case, the paired shell has an insert with astep 58 formed to cooperate with the insert of the paired shell. In thisway, a large number of uniquely paired connectors may be produced, eachwhich will not mate with unpaired shells, irrespective of keyingarrangements.

What is claimed is:

1. In an electrical connector having a pair of cooperating shells forcontaining contact bearing insert members and means for maintaining saidshells in coupled relation with each other, a pair of insert members forsaid shells, each of said insert members having a stepped surface withan extended surface portion and a recessed surface portion facing theinsert member of the opposite shell, a plurality of contact members of afirst type being mounted in fixed relationship with said insert memberin axial alignment with said extended surface portion, and a pluralityof contact members of a second type being mounted in fixed relationshipwith said insert member in axial alignment with said recessed surfaceportion, said contact members of a first type comprising pin typecontact members, and said contact members of a second type comprisingsocket type contact members, said pin type contact members eachcomprising a pin mounted within an aperture in said insert member andlocated within the extended portion of said insert, said socket membersextending beyond the recessed portion of said insert, the contactmembers of the second type extending toward the cooperating shell agreater distance than the contact members of the first type.

2. Apparatus according to claim 1, wherein said socket type contactmembers are each mounted on said insert member and extend beyond saidrecessed surface portion toward the insert member of the opposite shell.

3. Apparatus according to claim 2, wherein said socket type contactmembers extend beyond said pin type contact members.

4. Apparatus according to claim 1, including a layer of elastomericmaterial adjacent said recessed surface portion for engaging theextended surface portion of the insert member of the opposite shell whensaid shells are in coupled relation.

5. Apparatus according to claim 4, wherein said contact members of asecond type extend through said layer.

6. In an electrical connector having a pair of cooperating shells forcontaining contact bearing insert members and means for maintaining saidshells in coupled relation with each other, a pair of insert members forsaid shells, each of said insert members having a stepped surface withan extended surface portion and a recessed surface portion facing theinsert member of the opposite shell, a plurality of contact members ofafirst type being mounted in fixed relationship with said insert memberin axial alignment with said extended surface portion, and a pluralityof contact members of a second type being mounted in fixed relationshipwith said insert member in axial alignment with said recessed surfaceportion, the contact members of the second type extending toward thecooperating shell a greater distance than the contact members of thefirst type, said insert member comprising a plurality of superposedplate members having aligned apertures therein for mounting said contactmembers, each of said contact members being maintained in axialalignment by a pair of spaced apart shoulders provided on the interiorsurface of its aperture, one of said shoulders being located on one ofsaid plate members, and the other of said shoulders being located on adifferent one of said plate members.

7. Apparatus according to claim 6, wherein the plate member which ismost remote from the opposite shell is provided with a radiallyoutwardly extending flange engaging on one side a shoulder of the shellcontaining said insert member, and including a lock ring in fixedengagement with said shell, said lock ring engaging the other side ofsaid flange to support said insert member in fixed relation with saidshell.

1. In an electrical connector having a pair of cooperating shells forcontaining contact bearing insert members and means for maintaining saidshells in coupled relation with each other, a pair of insert members forsaid shells, each of said insert members having a stepped surface withan extended surface portion and a recessed surface portion facing theinsert member of the opposite shell, a plurality of contact members of afirst type being mounted in fixed relationship with said insert memberin axial alignment with said extended surface portion, and a pluralityof contact members of a second type being mounted in fixed relationshipwith said insert member in axial alignment with said recessed surfaceportion, said contact members of a first type comprising pin typecontact members, and said contact members of a second type comprisingsocket type contact members, said pin type contact members eachcomprising a pin mounted within an aperture in said insert member andlocated within the extended portion of said insert, said socket membersextending beyond the recessed portion of said insert, the contactmembers of the second type extending toward the cooperating shell agreater distance than the contact members of the first type. 2.Apparatus according to claim 1, wherein said socket type contact membersare each mounted on said insert member and extend beyond said recessedsurface portion toward the insert member of the opposite shell. 3.Apparatus according to claim 2, wherein said socket type contact membersextend beyond said pin type contact members.
 4. Apparatus according toclaim 1, including a layer of elastomeric material adjacent saidrecessed surface portion for engaging the extended surface portion ofthe insert member of the opposite shell when said shells are in coupledrelation.
 5. Apparatus according to claim 4, wherein said contactmembers of a second type extend through said layer.
 6. In an electricalconnector having a pair of cooperating shells for containing contactbearing insert members and means for maintaining said shells in coupledrelation with each other, a pair of insert members for said shells, eachof said insert members having a stepped surface with an extended surfaceportion and a recessed surface portion facing the insert member of theopposite shell, a plurality of contact members of a first type beingmounted in fixed relationship with said insert member in axial alignmentwith said extended surface portion, and a plurality of contact membersof a second type being mounted in fixed relationship with said insertmember in axial alignment with said recessed surface portion, thecontact members of the second type extending toward the cooperatingshell a greater distance than the contact members of the first type,said insert member comprising a plurality of superposed plate membershaving aligned apertures therein for mounting said contact members, eachof said contact members being maintained in axial alignment by a paiR ofspaced apart shoulders provided on the interior surface of its aperture,one of said shoulders being located on one of said plate members, andthe other of said shoulders being located on a different one of saidplate members.
 7. Apparatus according to claim 6, wherein the platemember which is most remote from the opposite shell is provided with aradially outwardly extending flange engaging on one side a shoulder ofthe shell containing said insert member, and including a lock ring infixed engagement with said shell, said lock ring engaging the other sideof said flange to support said insert member in fixed relation with saidshell.